Method for fast manufacturing and assembling of hot runner systems

ABSTRACT

The method and apparatus of the present invention includes a computer implemented injection molding configuring subsystem which enables a customer to interactively specify and design a system using a mix of parameters that the customer specifies and are manufacturing process determined. The configuring subsystem is connected to a computer network such as the Internet. The method and apparatus of the present invention further includes a computerized business and processing subsystem in communication with the configuring subsystem. The computerized business subsystem automatically provides a cost and schedule for a system configured by the configuring subsystem and additionally processes an order for the system. The processing subsystem automatically processes the customer&#39;s inputs and generates drawings for the configured system. Prior to receiving the customer&#39;s order, hot runner system components may be partially manufactured in a first phase and placed in inventory. The partially manufactured hot runner components may then be removed from inventory after receiving a customer&#39;s order, and further manufactured and assembled in accordance with the customer&#39;s parameters in a second phase.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of prior application Ser. No.10/720,017, filed Nov. 21, 2003, which is a continuation of priorapplication Ser. No. 09/595,154, now U.S. Pat. No. 6,675,055, filed Jun.16, 2000, entitled “Method and Apparatus for an Automated InjectionMolding Configuring and Manufacturing System,” and prior applicationSer. No. 09/595,133, now abandoned, filed Jun. 16, 2000, entitled“Method for Fast Manufacturing and Assembling of Hot Runner Systems,”both of which are specifically incorporated by reference herein in theirentirety.

FIELD OF THE INVENTION

This present invention relates to injection molding systems. Morespecifically, it relates to a method and apparatus for an automatedinjection molding configuring and manufacturing system.

The present invention also relates to a method for fast manufacturingand assembling of hot runner systems. More specifically, it relates to amethod of manufacturing and assembling customized hot runner systemsusing a wide selection of standard manifold plates, nozzles, and otherstock components.

BACKGROUND OF THE INVENTION

In many manufacturing businesses the time from the initial customercontact to the release of components or systems for production is acritical path. Current processes and tools in place in manymanufacturing processes, in particular, injection molding processescannot support the order volume desired by the manufacturers.

Injection molding is a process by which some malleable material isforced under pressure into a closed mold. The material solidifies andretains the shape of the mold. Thermoplastic materials, thermosettingmaterials and some ceramic materials can be processed in this way. In atypical injection molding process, a material is melted and injectedinto a mold that has been clamped shut. The material freezes in therelatively colder mold and is then ejected.

At the beginning of the molding cycle, the molten material is injectedinto the mold through a sprue bushing, runner, and gate. Duringinjection, the molten material (the “melt”) is subject to a coolingeffect by contact with the relatively lower temperature surface of themold, but is also subject to a heating effect due to viscous dissipationin the melt. If the cooling effect is greater than the heating effect,the plastic may solidify before the mold is filled, resulting in anunfilled mold, i.e. a “short shot”. If the heating effect dominates, themolding cycle may be unnecessarily extended for added cooling time.Because of the high volume rates of operation, even small gains orlosses of time can be significant. The melt temperature and injectionrate must be chosen so that neither of these problems occurs.

At the end of the injection period, the flow in the mold stops, thepressure rises rapidly, and the material begins to cool. As the materialcools it shrinks slightly and more material may be forced into thecavity to the hold pressure acting on the melt. This portion of themolding cycle is called the “hold” or the “packing stage”, and itcontinues until the hold pressure is released or until the gate freezes.After the gate has frozen, the material in the mold continues to cool,which at first causes a reduction in pressure, followed by shrinkage ofthe material in the cavity. When the molded part has cooled sufficientlyto remain rigid, the mold may be opened and pins eject the molded part,runner, and sprue from the mold.

Over the last decade, the techniques for designing, building, andordering injection molding processes have been improved to increaseproductivity. There are systems in place that support electronicversions of catalogs of injection molding components such as, thoseoffered by Mold Masters Limited, the assignee of this invention, HascoYudo, Dynisco, Heatlock, Mastip and the National Tool and ManufacturingCo. Further, interactive systems for selection of components fromstandard component lists such as Eurotool offered by Navigator are knownin the art. There are systems also in place that support automaticdrawing generation of injection molding systems. Further, there aresystems available that integrate a computerized business system with acomputerized manufacturing system.

However, even with recent improvements, the current injection moldingsystems have several drawbacks. Specifically, problem areas include theinadequacy of specification and order systems. For example, such systemsare typically confined to only limited off-the-shelf components andinformation. Further, some systems presently allow the user to specifyand order injection molding systems, such as hot runner systems, eventhough the person ordering has insufficient knowledge or experience tospecify the product design. The resulting product may not function ormay even result in a safety concern. In addition, current systems stillrequire manual human intervention downstream by the manufacturer'spersonnel such as, for example, by the engineers. Further, typically thecurrent manufacturing systems include the manual generation of themanufacturing information, such as the tooling information.

Accordingly, it is desirable to automate and integrate the design,specification, configuration and order systems with the business andmanufacturing systems to enable a real-time automated configuring andmanufacturing system which overcomes the problems associated with theprior art.

Hot runner systems for injection molding are well-known in the art. Hotrunner systems generally comprise a manifold plate with a plurality ofinjection nozzles. The manifold plates used in such hot runner systemscome in a variety of different shapes, configurations, and styles,depending on customer and/or manufacturing preferences. For example, themanifold plate may have a straight bar shape, X-shape, H-shape, Y-shape,Y-plate shape, or H-plate shape. In addition, the manifold plate may beconfigured with a wide range of lengths (e.g., 150 millimeters to 600millimeters) and thickness (e.g., 25 millimeters to 40 millimeters), andthe flow channels of the manifold plate may be configured with a widerange of diameters (e.g., 3 millimeters to 12 millimeters).

The number, pitch spacing, and type of nozzles used with the manifoldplate may also vary depending on customer and/or manufacturingpreferences. For instance, anywhere from 2 to 8 nozzles (or more) may beused with a manifold plate, and each nozzle may be spaced (i.e., nozzlepitch) anywhere from 30 mm to 250 mm away from the melt inlet of themanifold plate. Moreover, the nozzles may have a number of differentshapes, sizes, tips styles, gate configurations (e.g., thermal or valvegating), and shot weight ranges.

Obviously, it would be very impractical and expensive, if notimpossible, to pre-manufacture and pre-assemble all of the possibleexisting combinations of hot runner systems, and have them stored ininventory for delivering to a customer upon placing an order. Incontrast, it would be undesirable to unduly limit the shapes,configurations, styles, types, and/or sizes of the manifold plates andnozzles used in hot runners systems, and restrict customers' ability tocustomize their hot runner systems. Thus, in order to accommodate theirvarious designs and customers' custom specifications, hot runner systemsare typically not manufactured or assembled until after customers haveplaced orders for the hot runner systems and specified their designrequirements. Consequently, the manufacturing and assembling of such hotrunner systems can take several weeks, if not several months, tocomplete, since all of the work is done after the customer places anorder.

A typical hot runner system is manufactured and assembled with thefollowing prior art method. In the first step, a customer's order istaken by the hot runner maker, including the customer's specificationsfor the ordered hot runner system. Based on the customer'sspecifications, the raw material for the manifold is selected in thesecond step, and the manifold plate is manufactured in the third step bycutting and grinding the raw material into the desired manifold platedimensions. Next, in the fourth step, a heating element is added to themanifold plate, and in the fifth step, the main and auxiliary flowchannels are drilled in the manifold plate. Then, in the sixth step,holes for attachments to the manifold plate are drilled, bored, and/ormachined, and the specified injection nozzles are manufactured in theseventh step. Finally, in the eighth step, the specified components,including the injection nozzles, are attached to the manifold plate, andthe customized hot runner system is completed and delivered to thecustomer in the ninth step. As previously mentioned, this prior artmethod can take several weeks, if not months, to complete.

Accordingly, it would be desirable to provide a method for speeding upthe manufacturing and assembling processes involved with hot runnersystems to allow customers to receive their hot runner systems in ashorter period of time (i.e., in a matter of days, rather than weeks),yet still provide customers with the flexibility to customize their hotrunner systems. The present invention accomplishes this desire andovercomes the problems with the prior art by providing a method forquickly manufacturing and assembling customized hot runner systems usinga wide selection of standard manifold plates, nozzles, and other stockcomponents, such as manifold heating elements and plugs. The method ofthe present invention enables hot runner systems to be rapidly assembledfrom partially manufactured components, while still allowing customersto choose from a broad range of options for manifold plates andinjection nozzles, and to specify the requirements for their hot runnersystems.

SUMMARY OF THE INVENTION

The method and apparatus of the present invention includes an automatedinjection molding configuring and manufacturing system. A configuringsubsystem in accordance with the present invention, enables customers tointeractively create designs of their specific systems utilizing a website.

In accordance with a preferred embodiment, the method of the presentinvention includes, configuring an injection molding system using a mixof customer determined parameters and manufacturer determinedparameters. Further, the method includes using an input into theconfiguring subsystem for the generation of: (i) customer viewablemodels and drawings, (ii) engineering bill of materials, which may besubsequent input into a business subsystem, (iii) manufacturingdrawings, and (iv) the machine tool codes, setups, and required toollists. In a particular embodiment, the method of the present inventionincludes a processing subsystem that creates product drawings from theconfigured design. Further, the method includes verifying the configureddesign to ensure that the injection molding system specified isfunctional and safe.

In accordance with another aspect of the present invention, an automatedinjection molding configuring and manufacturing system includes aconfiguring subsystem for designing a custom designed injection moldingsystem using a mix of customer defined parameters and manufacturerdefined parameters. The system further includes a business subsystemand/or a processing subsystem in communication with the configuringsubsystem.

The foregoing and other features and advantages of the method andapparatus for an automated injection molding configuring andmanufacturing system will be apparent from the following more particulardescription of preferred embodiments of the method and apparatus asillustrated in the accompanying drawings.

Moreover, the present invention provides a method for manufacturing andassembling hot runner systems comprising the steps of manufacturing aplurality of manifold plates, injection nozzles, and plugs, and addingheating elements to the manifold plates. The method of the presentinvention also comprises the steps of drilling flow channels into themanifold plates, and placing the manifold plates, the injection nozzles,and the plugs in stock. The method of the present invention furthercomprises the steps of taking orders with specifications for hot runnersystems, and removing from stock the manifold plates, the injectionnozzles, and the plugs that correspond to the specifications of theorders. In addition, the method of the present invention comprises thesteps of boring out holes for the plugs in the manifold plates atlocations that correspond to the specifications of the orders, insertingthe plugs into the bored out holes of the manifold plates, and attachingthe nozzles to the manifold plates in alignment with the plugs.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present inventions are described withreference to the following drawings, wherein:

FIG. 1 is a diagram illustrating a preferred embodiment of theconfiguring and manufacturing system in accordance with the presentinvention;

FIGS. 2 a and 2 b are flowcharts illustrating a preferred embodiment ofthe system in accordance with the present invention;

FIG. 3 is an illustration of a computer screen display showing the loginentry process into the configuring subsystem in accordance with aparticular embodiment of the present invention;

FIG. 4 is an illustration of a computer screen display of the optionsoffered by a particular embodiment of the configuring subsystem inaccordance with the present invention;

FIG. 5 is an illustration of a computer screen display of theconfiguring options offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 6 is an illustration of a computer screen display of the customerinputs relating to material weight and selection in accordance with aparticular embodiment of the present invention;

FIG. 7 is an illustration of a computer screen display of the productline options offered by a particular embodiment of the configuringsubsystem in accordance with the present invention;

FIG. 8 is an illustration of a computer screen display of the gatingoptions offered by a particular embodiment of the configuring subsystemin accordance with the present invention;

FIG. 9 is sectional view of a portion of a multi-cavity valve gatedinjection molding system showing a one-piece gate and locating insertaccording to one electronic catalog page offered by a particularembodiment of the configuring subsystem of the present invention;

FIG. 10 is a sectional view of a portion of a multi-gate injectionmolding system showing a torpedo according to one electronic catalogpage offered by a particular embodiment of the configuring subsystem inaccordance with the present invention;

FIG. 11 is a partial sectional view of a portion of a multi-cavityinjection molding system according to one electronic catalog page inaccordance with a particular embodiment of the present invention;

FIG. 12 is a sectional view of a portion of a side gated molding systemin the closed position according to one electronic catalog page inaccordance with a particular embodiment of the present invention;

FIG. 13 is an illustration of a computer screen display of the systemtype and gating method selection as displayed by a particular embodimentof the configuring subsystem in accordance with the present invention;

FIG. 14 is an illustration of a computer screen display of the gate sealselection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 15 is an illustration of a computer screen display of the nozzleselection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 16 is an illustration of a computer screen display of the nozzlequantity selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIGS. 17 and 18 are illustrations of computer screen displays of themanifold configuration selection process as offered by a particularembodiment of the configuring subsystem in accordance with the presentinvention;

FIG. 19 is a sectional view showing a portion of a multi-cavityinjection molding system with a melt distribution manifold according toone electronic catalog page offered by a particular embodiment of theconfiguring subsystem of the present invention;

FIG. 20 is a sectional view of a portion of an injection molding systemhaving four heated nozzle manifolds connected to a central manifold in apartially assembled mold according to one electronic catalog page asoffered by a particular embodiment of the configuring subsystem of thepresent invention;

FIG. 21 is a sectional view showing a nozzle manifold after assembly ofthe mold has been completed as offered by one electronic catalog page ofthe configuring subsystem in accordance with a particular embodiment ofthe present invention;

FIG. 22 is a sectional view showing a portion of a multi-cavityinjection molding system with a melt distribution manifold according toone electronic catalog page offered by a particular embodiment of theconfiguring subsystem of the present invention;

FIG. 23 is an illustration of a computer screen display of the gateinsert selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 24 is an illustration of a computer screen display of the valueactuator selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 25 is an illustration of a computer screen display of the inletcomponent selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 26 is an illustration of a computer screen display of the inletcomponent manifold center heater selection process as offered by aparticular embodiment of the configuring subsystem in accordance withthe present invention;

FIG. 27 is an illustration of a computer screen display of the locationring selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 28 is an illustration of a computer screen display of the moldingelevation selection process as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 29 is an illustration of a computer screen display of the customerinformation form as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 30 is an illustration of a computer screen display of the summaryinformation form as offered by a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 31 is an illustration of a computer screen display of the list ofgenerated drawings offered by a particular embodiment of the configuringsubsystem in accordance with the present invention;

FIG. 32 is a sectional view of a multi-cavity injection molding systemhaving a manifold as defined using a particular embodiment of theconfiguring subsystem in accordance with the present invention;

FIG. 33 is an illustration of a computer screen display of theconfiguring options selecting the existing configurations option asoffered by a particular embodiment of the configuring subsystem inaccordance with the present invention;

FIG. 34 is an illustration of a computer screen display of the existingconfigurations as offered by a particular embodiment of the configuringsubsystem in accordance with the present invention;

FIG. 35 is an illustration of a computer screen display of the summaryinformation form as offered as a result of existing configurationsoption in accordance with one particular embodiment of the presentinvention;

FIG. 36 is a block diagram illustrating a preferred method of thepresent invention for manufacturing and assembling a hot runner system.

FIG. 37 is a flow diagram illustrating a preferred method of the presentinvention for manufacturing and assembling a hot runner system.

FIG. 38A-38J are perspective views of a partial straight bar, two nozzlehot runner system that is manufactured and assembled according to themethod of FIG. 37.

FIG. 38K-38M are detailed top and side views of the partial straightbar, two nozzle hot runner system of FIG. 38J, as well as partialexemplary X-shaped and H-shaped, four nozzle hot runner systems,together with tables for preferable nozzle pitches and manifolddimensions for such hot runner systems.

FIG. 39 is a partial cross-sectional view of a plug of the hot runnersystem of FIG. 38J, taken along line 4-4.

FIG. 40 is a side cross-sectional view of the plug of FIG. 39 rotatedinto a lateral position and parallel orientation.

FIG. 41 is a partial side cross-sectional view of the plug of FIG. 40positioned within a modified bore that has been rotated into a lateralposition and parallel orientation corresponding to the plug.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is directed to systems and methods for automatingand integrating injection molding configuring and manufacturing systems.

The operating environment for the methods and apparatus for theinjection molding configuring and manufacturing system of the presentinvention includes a processing system with at least one high speedprocessing unit and a memory system. In accordance with common practicesin the art of computer programming, the description below includesreference to acts and symbolic representations of operations orinstructions that are performed by the processing system, unlessindicated otherwise. Such acts and operations or instructions aresometimes referred to as being “computer-executed” or “processing unitexecuted.”

It will be appreciated that the acts and symbolically representedoperations or instructions include the manipulation of electricalsignals by the computer processing unit. An electrical system with databits causes a resulting transformation or reduction of the electricalsignal representation, and the maintenance of data bits at memorylocations in the memory system to thereby reconfigure or otherwise alterthe processing unit's operation, as well as other processing of signals.The memory locations where data bits are maintained are physicallocations that have particular electrical, magnetic, optical, or organicproperties corresponding to the data bits.

The data bits may also be maintained on a computer readable mediumincluding magnetic disks, optical disks, organic disks, and any othervolatile or non-volatile mass storage system readable by the processingunit. The computer readable medium includes cooperating orinterconnected computer readable media, which exist exclusively on theprocessing system or is distributed among multiple interconnectedprocessing systems that may be local or remote to the processing system.

The systems may be implemented using, but not limited to, the softwareand standards such as, for example, an IDEAS Master Series 7m2 runningon Windows NT, SAP 4.6 running on Windows NT 4.0 (service pack 2),Microsoft Visual C++ (v5.0), and HTML version 3.0. However, it ispossible to use other applications, languages, standards, and/oroperating systems such as UNIX, LINUX or others.

FIG. 1 illustrates a preferred embodiment of the system 10 in accordancewith the present invention which is used to configure and manufactureinjection molding systems. The system 10 includes a configuringsubsystem 12 which is a web-based, designing and ordering aconfiguration subsystem. A customer 20, can use the configuringsubsystem 12 which is in communication with a web server using a browserapplication. The information present in the configuring subsystem 12includes, but is not limited to, components, such as, locating rings,melt entries, manifolds, center locators, manifold cam locators, nozzleflanges, nozzles, actuators, and valves or pressure disks.

The configuring subsystem 12 receives a variety of inputs from thecustomer 20. These customer inputs include, but are not limited to,frame length, frame width, frame height, insulator plate, such as, forexample, selecting between a “yes” or “no” option regarding theinsulator plate, size, mold elevation, clamp slot details, water fittingtype and size, leader pin size and position, guide pin size, screw sizeand position, clearance pockets size and position, mold foot, pry-slotand customer wire schematic and type of connector.

The system 10 includes a business subsystem 14 which processes thevarious bills and maintains cost and status information from the step ofsystem quotation to the step of delivery of injection molding systems.In one particular embodiment, the business subsystem 14 is typical of abusiness transaction processing system. An example of the businesssubsystem 14 is the Enterprise Resource Planning (ERP) system, such as aSAP system.

The system 10 further includes a processing subsystem 16 which is acombination of custom software and general application softwarepackages. It generates drawings based on the customer 20 input into theconfiguring subsystem 12.

The system 10 further includes a drawing subsystem 18 which generatestwo and three dimensional customer drawings and models. The drawingsubsystem 18 also generates manufacturing tool lists and setupinformation.

FIGS. 2 a and 2 b are flowcharts illustrating a preferred embodiment ofthe system in accordance with the present invention. The method beingsat step 52 with a user or a customer logging into a digital network suchas, the Internet or an Intranet. The Internet typically comprises a vastnumber of computers in computer network that are interconnected throughcommunication links. The interconnected computers exchange informationusing various services, such as, electronic mail, and the world wide web(“WWW”). The WWW service allows a server computer system for example, aweb server or a web site to send graphical web pages of information to aremote customer computer system 20. The remote customer computer systemcan then display web pages. Each resource for example, a computer or webpage of the WWW is uniquely identifiable by a Uniform Resource Locator(“URL”). To view a specific web page, a customer computer system 20specifies the URL for the web page in the request, for example, in aHyperText Transfer Protocol request. The request is forwarded to the webserver that supports that web page. When that web server receives therequest, it sends that web page to the customer computer system 20. Whenthe customer computer system receives that web page, it typicallydisplays that web page using a browser. A browser is a special purposeapplication program that effects the requesting and the displaying ofweb pages. Any WWW browser on any personal computer platform, such as,but not limited to, Macintosh, Windows 95, Windows NT, and DOS, may beused.

Web pages are typically defined using HyperText Markup Language(“HTML”). HTML provides a standard set of texts that define how a webpage is to be displayed. When a user instructs the browser to display aweb page, the browser sends a request to the server computer system totransfer to the customer computer system the HTML, document that definesthe web page. When the requested HTML document is received by thecustomer computer system, the browser displays the web page as definedby the HTML, document. The HTML, document contains various texts thatcontrol the displaying of texts, graphics, control and other features.

The WWW is specially conducive to conducting electronic commerce. Theweb server computer system may provide an electronic version of acatalog that lists the items that are available. Thus the user at step52 logs in to the WWW at step 54. Once the user has gained access intothe system, the user is offered two options. The first being at step 56,the user is given an option to look up a previous configuration. In thesecond option at step 58, the user can choose the option of configuringa new injection molding system. At step 62, once the user has opted toconfigure a new system, the user accesses the configuring subsystem 12.The configuring subsystem 12 then interacts with the other subsystems insystem 10 such as, the processing subsystem 16 and the businesssubsystem 14 as described with respect to FIG. 1. At step 64, the userthen chooses if they want to generate a drawing for their system thatwas just configured or get a cost or a quote for the configuration thatthey specified, or they can get schedule information and order theconfiguration they just defined. The same option at step 64 is alsoavailable to a user who had chosen to look up a previous configurationat step 56 which in turn accesses an archive database 60.

If the user decides to generate a drawing of the configured injectionmolding system at step 64, then a file of characteristics or processedcustomer inputs are accessed per step 66 for the drawing subsystem 18.The resulting characteristics are sent to the drawing subsystem at step68. The drawing subsystem 18 then generates the drawings at step 70. Thedrawings are saved to a file system in the server, per step 74. Thecustomer then gains access to the generated drawings using, but notlimited to, an electronic mail link that is provided to the customer perstep 74.

If at step 64 the customer or user had determined to get a quote or acost estimate for the configured system, then a file of characteristicsis accessed for the business subsystem at step 80. The file ofcharacteristics is sent to the business subsystem 14 at step 82. Thebusiness subsystem 14 then processes the processed inputs orcharacteristics and enters a quote into the system at step 84. At step86, the quote containing the quantities and prices may then be displayedto the customer in the configuring subsystem 12. The customer at thispoint can choose to effectuate an order based on the return quote atstep 88.

If the customer had chosen to determine the lead time and schedule forthe configured system at step 64, then the information required todetermine the schedule information is accessed at step 90. The quoteinformation is sent to the configuring subsystem 12 at step 92 whichprocesses the information and returns a schedule and lead time to aconfiguring subsystem 12 which can be viewed by the customer. At step96, this particular schedule can be implemented into an order by thecustomer. Upon configuring the system using the configuring subsystem12, the user can use step 64 to directly order the configuration withoutthe need to generate drawings or get a quote or schedule information forthe configuration. At step 100, the file of characteristics is accessedfor the business subsystem 14. These characteristics are sent to thebusiness subsystem 14 at step 102. The business subsystem at step 104processes the order. At step 106, an electronic mail notification issent to the verifying personnel, such as an application engineer. Atstep 108, the verifying personnel reviews the configured system toverify the functionality, safety, manufacturability and applicability ofthe customized design. Once positively reviewed, the order is completedat step 110, and an electronic mail confirmation is sent to the customerat step 112. If the review is not favorable, then per step 114, anelectronic mail request for further information or alterations is sentto the customer to ensure a design that is manufacturable, functional,and safe.

FIG. 3 is an illustration of a computer screen display 100 showing thelogin entry process into the configuring subsystem in accordance withone particular embodiment of the present invention. The configuringsubsystem 12 is password protected in the interest of security, asindicated by the login menu in the password entry area 102 shown in thecomputer screen display 100. The “security” of the system could beprovided through any of the many techniques known in that field. Theconfiguring subsystem 12 provides the ability for a customer to customdesign, order and track the delivery of injection molding systems. Theconfiguring subsystem 12 is an interactive expert system which isintuitive and easy to use by a customer.

FIG. 4 is an illustration of a computer screen display 110 of theoptions offered by a particular embodiment of the configuring subsystemin accordance with the present invention. The configuring subsystem 12has four options offered to the customer 20, once they have accessed thesystem after going through the security measures of logging in asdescribed with respect to FIG. 3. The computer screen display 110illustrates the four options, one being the option to configure a system112, the second being the option to view a catalog 114, the third beingthe option to order spare parts 116 and the fourth being the option toperform an order inquiry 118. The “configure a system” 112 option allowsthe customer to select components to either configure a new system oraccess an existing system from previously saved systems. The option ofviewing a catalog 14 allows a customer a view electronic versions ofcomponent catalog or system catalog pages. The option to order spareparts 116 is an order entry system which allows the customer to orderextra parts for existing systems. The option of order inquiry 118 allowsa customer to view orders that were previously entered or view a listingof current orders. In addition, the order inquiry option 118 lists thestatus of orders.

FIG. 5 is an illustration of a computer screen display 120 ofconfiguring options offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thecomputer screen 120 illustrates the selection options under the“configure a system” option 112. The customer is asked to make aselection between a “configure a new system” option 122, or an “existingconfigurations” option 124. The “configure a new system” option 122allows the customer to configure a system and save it to their account.The existing configurations system option 124 allows the customer toaccess an existing system from the list of saved systems.

FIG. 6 is an illustration of a computer screen display 130 of thecustomer inputs relating to material weight and selection in accordancewith the present invention. Once the “configure a new system” option 122has been chosen as discussed with respect to FIG. 5, the customer isthen asked to input a shot weight, material, and fill up percentagesinformation into a user input display. The shot weight, material andfill up percentages can be selected from pull down menus that areavailable. Another option, in this computer screen display 130 is thatthe shot weight 132, material 134, and fill up percentages 136 can bemanually entered in the respective input graphical selection inputs.

FIG. 7 is an illustration of a computer screen display 140 of theproduct line options offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thecustomer is prompted as shown on screen 140 to select a product linethat is provided by the manufacturer by clicking on a correspondingbutton placed below the options, such as, the graphical selection input142 for Dura™, the MIM Dura-Shot® graphical selection input 144, thegraphical selection input 146 for MIM Speed™, or the Flex Dura™ Systemgraphical selection input 147. There is a brief description pertainingto each of the four product lines. Although the screen display 140 showsfour product lines, the present invention is not limited to just thefour product lines. The trademarks and products shown here forillustration are obtained from Mold-Masters Limited, of Georgetown,Ontario, Canada. Different manufacturers would be expected to supplytheir own information. More or fewer product lines can be offered to acustomer.

FIG. 8 is an illustration of a computer screen display 150 of the gatingoptions offered by a particular embodiment of the configuring subsystem12 in accordance with the present invention. The computer screen display150 is the next sequential screen after the computer screen 140described with respect to FIG. 7. The customer 20 is queried to choosebetween the different gating technologies that they would like to use.The options that are presented in the example illustrated include avalve gate 152, a sprue gate 154, an edge gate 156, and a tip gate 158.The customer is provided with information regarding all the gatingtechnologies provided. Although there are four gating technologiesdescribed herein, the screen 150 can include fewer or more gatingtechnologies.

FIG. 9 is sectional view of a portion of a multi-cavity valve gatedinjection molding system 170 showing a one-piece gate and locatinginsert according to one electronic catalog page offered by a particularembodiment of the configuring subsystem 12 in accordance with thepresent invention. The injection molding system 170 of this example isdescribed in a U.S. Pat. No. 5,849,343, which issued on Dec. 15, 1998,and is incorporated herein by reference. The customer can make changesto many different dimensions of the multi-cavity valve gated injectionmolding system 170 such as, for example, to the dimensions of thecylinder 172 and to the area of the nozzle 174.

FIG. 10 is a sectional view of a portion of an illustrative multi-gateinjection molding system 180 including a torpedo 192, according to oneelectronic catalog page offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Theinjection molding system 180 of this example is described in a U.S. Pat.No. 5,658,604, which issued on Aug. 19, 1997, and is incorporated hereinby reference. The system 180 has a melt distribution manifold 184interconnecting several heated nozzles 186 in a mold 188. The customercan change several dimensions, such as, for example, the dimension ofthe front end 190 of each nozzle 186 as well as the dimensions of thetorpedo 192.

FIG. 11 is a partial sectional view of a portion of an illustrativemulti-cavity injection molding system 200 according to one electroniccatalog page in accordance with the present invention. The injectionmolding system 200 of this example is described in a U.S. Pat. No.5,421,716, which issued on Jun. 6, 1995, and is incorporated herein byreference. The multi-cavity injection molding system 200 has severalsteel nozzles to convey pressurized plastic melt through melt passage206 to respective gates 208 leading to a different cavity 210 in themold 212. The customer can change and configure the system by definingtheir own dimensions such as, for example, defining the dimensions forthe cylindrical opening 214.

FIG. 12 is a sectional view of a portion of an illustrative side gatedmolding system 220 in the closed position according to one electroniccatalog page in accordance with the present invention. The injectionmolding system 220 of this example is described in a U.S. Pat. No.5,952,016, which issued on Sep. 14, 1999, and is incorporated herein byreference. The multi-cavity injection molding system 220 has severalheated steel nozzles 224 extending from a heated steel melt distributionmanifold 226 in a mold 228 to convey pressurized melt to the meltpassage 230 to several gates 232 spaced around each heat nozzle 224. Thecustomer can change the dimensions such as, the length 222 between thecentral cooling conduits 234.

FIG. 13 is an illustration of a computer screen display 240 of thesystem type and gating method selection as displayed by a particularembodiment of the configuring subsystem 12 in accordance with thepresent invention. This computer screen display 240 itemizes the systemtype chosen, such as the MIM Speed Dura Hecto-Shot system 242, and thegating method selected, such as the Bi-Metallic C-Value 244. It furtherprovides recommendations for further options if the configured designchosen up to this point, such as the system type and gating methodology,is suitable for the functional system as shown in the graphicalselection input 246. In addition, the screen provides visibility intothe electronic versions of the catalog pages as viewed by clicking onthe graphical selection input “view” 248.

FIG. 14 is an illustration of a computer screen display 260 of the gateseal selection process as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Asdisplayed in right hand side of the screen, the customer is asked tochoose several components and system elements, such as the gate seal262, a nozzle 264, a manifold 266, and so on. In this exemplaryembodiment, the first component that the customer can specify once thesystem type and gating methodology has been selected previously is thegate seal 262. The customer is prompted to get more information from theelectronic version of the catalog, or to provide her own specification,or to select the gate seal provided by the configuring subsystem in thematch graphical selection input 268. The gate seal number with theappropriate descriptions such as, diameters and ranges are displayed forthe match graphical selection input 268 configuring subsystem selection.Further, catalog pages of the gate seal selected by the configuringsubsystem 12 can be viewed by clicking on the graphical selection input270 along with the option of accessing computer-aided design (CAD)drawings by clicking on the graphical selection input 272.

FIG. 15 is an illustration of a computer screen display 280 of thenozzle selection process as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thenext component, once the gate seal 262 has been chosen, is typically thenozzle component 264. Once again the customer can provide the dimensionsfor a nozzle or select dimensions of matches that the configuringsubsystem 12 returns based on the selected system and gating technology.In this example, four matches 282, 284, 286, and 288 have been returnedas possible nozzle selections for the customer selected system andgating technology. The relevant catalog pages can be viewed by clickingon the graphical selection input 290 and corresponding drawings can bedownloaded by the customer by clicking on the download graphicalselection input 292.

FIG. 16 is an illustration of a computer screen display 300 of thenozzle quantity selection process as offered by a particular embodimentof the configuring subsystem 12 in accordance with the presentinvention. The computer screen display 300 is the next logical step inconfiguring the system per a customer specified parameter. Once thenozzles have been chosen as described with respect to FIG. 15, thenumber of nozzle selection occurs. The customer can input his selectionor take guidance from the recommendation of the configuring subsystem12. The configuring subsystem 12 for this particular example hasreturned a choice of two nozzles 302 or four nozzles 304. Catalog pageswhich are the electronic versions of the manufacturer's catalogs can beviewed by clicking on a graphical selection input, such as graphicalselection input 306, and similarly CAD drawings for each of thecorresponding nozzles can be downloaded by clicking the graphicalselection input download 308.

FIGS. 17 and 18 are illustrations of computer screen displays 320, 340of the manifold configuration selection process as offered by aparticular embodiment of the configuring subsystem 12 in accordance withthe present invention. The computer screen display 320 which displays amanifold configuring selection screen is the next sequential step thatthe customer follows to configure an injection molding system based ontheir specific parameters. The customer can click on the graphicalselection input standard sub-manifold 324 in order to enter thedimensions for a manifold using their parameters. The customer caneither work with the recommendations of the configuring subsystem 12which provides a manifold that could function with the system as definedup to this stage. Electronic versions of the configuring subsystem 12recommendations for the manifold configurations can be viewed byclicking on graphical selection input 326. Corresponding CAD drawing forthe recommended manifold can be downloaded by clicking on the graphicalselection input download 328. If the customer wants to configure amanifold completely based on their specific dimensions, the customer canrespond to a prompt in the screen display 340, and enter his dimensionsin graphical selection input 342. Once again, if there are any relevantcatalog pages of the electronic versions of the catalog, the customercan view them for the dimensions specified by activating the “view”graphical selection input 344. Drawings for the configuration can bedownloaded by clicking on the graphical selection input 346.

FIG. 19 is a sectional view showing a portion of an illustrativemulti-cavity injection molding system 360 with a melt distributionmanifold according to one electronic catalog page offered by aparticular embodiment of the configuring subsystem 12 in accordance withthe present invention. The injection molding system 360 is described ina U.S. Pat. No. 5,366,369, which issued on Nov. 22, 1994 and isincorporated herein by reference. The multi-cavity injection moldingsystem 360 has a steel melt distribution manifold 362 mounted in a mold364 between a cavity plate 366 and a back plate 368. The customer canchange many dimensions and can specify a manifold to suit her design,such as specifying the dimensions of a steel insert 370, which isremovably located in a transverse opening 372 through the manifold 362in alignment with each of the nozzles 374.

FIG. 20 is a sectional view of a portion of an illustrative injectionmolding system 380 having four heated nozzle manifolds connected to acentral manifold in a partially assembled mold according to oneelectronic catalog page as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Theinjection molding system 380 is described in a U.S. Pat. No. 5,707,664,which issued on Jan. 13, 1998 and is incorporated herein by reference.The injection molding system 380 includes four heated nozzle manifolds382 connected to a heated central manifold. The arrangement of thevarious manifolds in connection with the bushing and the configurationof the melt passage 376 ensures that the length melt flow to each gate378 in the system is exactly the same. The customer can change differentdimensions of the manifold such as, length, width and height.

FIG. 21 is a sectional view showing an illustrative nozzle manifold 400after assembly of the mold has been completed as offered by oneelectronic catalog page of a particular embodiment of the configuringsubsystem 12 in accordance with the present invention. The injectionmolding system 400 is described in a U.S. Pat. No. 5,705,202, whichissued on Jan. 6, 1998 and is incorporated herein by reference. Amanifold 402 is centrally located by a central locating ring 404 seatedbetween it and a mold 406. The customer can change several of thedimensions of the manifold such as, the length, width and height of themanifold as well as the placement of the nozzles.

FIG. 22 is a sectional view showing a portion of an illustrativemulti-cavity injection molding system 420 with a meld distributionmanifold according to one electronic catalog page offered by aparticular embodiment of the configuring subsystem 12 in accordance withthe present invention. The injection molding system 420 is described ina U.S. Pat. No. 5,441,197, which issued on Aug. 15, 1995 and isincorporated herein by reference. The melt distribution manifold 422 isnormally mounted in a mold 424 to interconnect a number of spacednozzles 426 to provide a multi-cavity injection molding system 420. Thecustomer can make modifications to different portions of the system 420.In particular, the customer can specify the dimensions for portions suchas, an elbow 428, the heating element 430, and but not limited to, aninsulated inlet portion 432.

FIG. 23 is an illustration of a computer screen display 440 of the gateinsert selection process as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thegate insert selection for example, selecting a water cooled gate insert442 is the next sequential step a customer is guided through toconfigure an injection molding system. The customer can either choose agate insert that the configuring subsystem 12 returns after doing someanalysis, or the customer can specify a gate insert of their owndimensions. If the customer chooses to select a recommended gate insert,then they can view the different options using a graphical selectioninput, such as graphical selection input 444, that represents electronicversions of the catalog with representative information about the gateinsert. In addition, the customer can access CAD drawings for thecorresponding gate insert using the graphical selection input 446.

FIG. 24 is an illustration of a computer screen display 460 of the valueactuator selection process as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thecustomer is guided to specify a value actuator 462 using either arecommended valve actuator provided by the configuring subsystem 12 orallowing the customer to specify the dimension of the valve actuator. Ifthe customer chooses to use the valve actuator as recommended by theconfiguring subsystem 12, she can access the recommendation by clickingon the graphical selection input 464 that provides relevant informationregarding the dimensions and the functionality of the valve. Further,the customer can review electronic catalog pages of the recommendedactuator using the “view” graphical selection input 464. The customercan also access the corresponding CAD drawing using the graphicalselection input 468.

FIG. 25 is an illustration of a computer screen display 480 of the inletcomponent selection process as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thedefinition of the inlet component 482 is the next sequential step thatthe configuring subsystem 12 provides to a customer in order for her toconfigure a custom injection molding system. The configuring subsystem12 provides a recommended inlet component such as, for example, themanifold center heater as displayed under match one in graphicalselection input 484. If the customer selects a recommended inletcomponent, she can view the electronic version of the catalog whichprovides more information about the inlet component by clicking on theview graphical selection input 486. CAD drawing can be downloaded andviewed using the graphical selection input 488.

FIG. 26 is an illustration of a computer screen display 500 of the inletcomponent manifold center heater selection process as offered by aparticular embodiment of the configuring subsystem 12 in accordance withthe present invention. The configuring subsystem guides the selection ofadditional inlet components for the system being specified by thecustomer such as, the inlet component manifold center heater. Asdescribed hereinbefore, the configuring subsystem 12 allows the customerto either use a recommended inlet component manifold center heater orspecify the customer's own parameters. The recommendation provided bythe configuring subsystem 12 can be viewed using the graphical selectioninput such as, for example, graphical selection input 502 which providesdimensions of the heater. Relevant catalog pages can be electronicallyaccessed using the “view” graphical selection input 504 for each of therecommended inlet components. CAD drawing can be downloaded for thecorresponding recommended components using the graphical selection input506.

FIG. 27 is an illustration of a computer screen display 520 of thelocation ring selection process as offered by a particular embodiment ofthe configuring subsystem 12 in accordance with the present invention.The selection for the locating ring 522 is the next sequential step thatthe configuring subsystem guides a customer through in completing thedefinition of their injection molding system. The configuring subsystem12 returns viable matches for the locating ring option such as, option 1as shown in the graphical selection input 524. Relevant catalog pagessuch as a page that can be viewed by clicking on graphical selectioninput view 526 provides information from an electronic version of acatalog for each of the locating rings and components selected up tonow. In addition, the CAD drawing corresponding to the locating ring canbe accessed and downloaded using the graphical selection input download528.

FIG. 28 is an illustration of a computer screen display 540 of themolding elevation selection process as offered by a particularembodiment of the configuring subsystem 12 in accordance with thepresent invention. A customer is queried as to the inclusion of amolding elevation. If the customer chooses to add information regardingmolding elevation, he can enter the dimension into the configuringsubsystem 12. The relevant catalog pages can be viewed by clicking on“view” graphical selection input 542 which provides electronic versionsof the system components that comprise the system that has beenconfigured by the customer. Corresponding CAD drawings for each of thecomponent can be downloaded using the download graphical selection input544.

FIG. 29 is an illustration of a computer screen display 560 of thecustomer information form as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Oncethe customer has defined and configured his system as described withrespect to the previous figures, the configuring process is followed byan information gathering process such as, for example, the applicationform being completed by the customer. The customer is prompted to fillout their name, address and reference number. The customer referencenumber is any number the customer wants to assign to itself. Inaddition, there are pull-down menus that support additional informationthat is gathered such as, process temperature 562, injection time 564,and gate cooling 566.

FIG. 30 is an illustration of a computer screen display 580 of thesummary information form as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Thesummary information form uses the information that has been inputtedinto the application information form as discussed with respect to FIG.29 and provides verification to check the correctness of the inputtedcustomer information. The summary information form provides differentoptions to the customer for example, the customer is prompted to savethe configured system using the “save” graphical selection input 582.Another option is to receive a quote for the configured system in termsof cost as provided using the “quote” graphical selection input 584. Inaddition, the customer is offered an option to have the configuredsystem viewed by an application engineer by looking at an electronicfile of the configured system, who ensures that the configured system isfunctionally sound and would not cause any safety or reliabilityconcerns. The customer simply has to click the review graphicalselection input 586 for an application engineer to get access to anelectronic version of the configured system created by the configuringsubsystem 12. In addition, the customer can place an order for theconfigured system simply by clicking on the graphical selection input“order” 588. Drawings for the customer showing the configured system canbe generated and provided simply by clicking on the “generate drawing”graphical selection input 590. Towards the latter part of screen 580, aschematic of the configured system is displayed from the electronicversion of the manufacturer catalog along with the summary informationthat was inputted as described with respect to the FIG. 29.

FIG. 31 is an illustration of a computer screen display 600 of the listof generated drawings offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Ifthe customer has requested generated drawings for the configured system,a screen of generated drawing 600 is provided to the customer for eitherdownloading or viewing online. The drawings come in several formats,such as, but not limited to, .tif format, .dxf format, .igs format, and.wrl format. The .wrl format provides a three dimensional virtualreality model of the configured system. Each of the figures for therespective formats either has a download option such as, by clickinggraphical selection input 602 or a viewing option such as, by clickingviewing graphical selection input 604.

FIG. 32 is a sectional view of an illustrative multi-cavity injectionmolding system 620 having a manifold as defined using the configuringsubsystem 12 in accordance with one particular embodiment of the presentinvention. The injection molding system 620 is described in a U.S. Pat.No. 5,007,821, which issued on Apr. 16, 1991 and is incorporated hereinby reference. FIG. 32 is a representative drawing that a customer canaccess using the generated drawing option as discussed with respectiveFIG. 30. The multi-cavity injection molding system 620 has a number ofheated nozzles 622 extending from a common heated manifold 624 asdefined by the customer during the process of configuring the system asdescribed with respect to FIG. 3 through FIG. 31.

FIG. 33 is an illustration of a computer screen display 640 of theconfiguring options selecting the “existing configurations” option 124as offered by a particular embodiment of the configuring subsystem 12 inaccordance with the present invention. As discussed with respect to FIG.5, the configuring subsystem 12 offers an option to access and viewexisting configurations from a list of saved systems. Once the customerhas created a configured system, she can at a later time logon per theprocess described with respect to FIG. 3 and access the configuringoption 124.

FIG. 34 is an illustration of a computer screen display 660 of theexisting configurations as offered by a particular embodiment of theconfiguring subsystem 12 in accordance with the present invention. Theexisting configuration screen display 660 accesses the existingconfigured system, such as the configuration “previous config” 662, ascreated with respect to FIG. 3 through FIG. 32. The customer can go inand check the status 664 and reference a quote number 666. The customercan also manipulate the existing configuration by either copying inorder to create a new configured system or delete the existingconfiguration.

FIG. 35 is an illustration of a computer screen display 680 of thesummary information form as offered as a result of existingconfigurations option 124 in accordance with one particular embodimentof the present invention. Once the existing configuration has beenselected using the previous screen 660 described with respect to FIG.34, a summary information screen display 680 can be used by the customerto verify the information previously inputted and then take additionalaction in terms of either saving the configured system using thegraphical selection input 682, getting a quote at this time for theconfigured system using the “quote” graphical selection input 684 orhaving the system previously configured be reviewed by applicationengineers by clicking on the “review” graphical selection input 686. Thecustomer can at this point also just order the previously configuredsystem using a graphical selection input 688. In addition, the customercan at this time request generated drawings displaying the configuredsystem using the graphical selection input 670.

It should be noted that even though the methods discussed with respectto the FIGS. 3 through 35 have been presented as a sequential flow ofconfiguring and ordering a system, the methods may include the userbreaking the sequence by accessing previous screen displays or optionsto exit from each definition stage. The method and apparatus of thepresent invention is implemented without the need of any communicationor human intervention between a purchasing party, such as the customer,and the personnel of the manufacturing party other than thecommunications provided by the computer-implemented system of thepresent invention. The method and apparatus of the present inventionresults in reductions to the cost and shortening of the schedule todesign, configure, order and manufacture an injection molding system.

It should be understood that the programs, processes, methods andsystems described herein are not related or limited to any particulartype of computer or network system (hardware or software), unlessindicated otherwise. Various types of general purpose or specializedcomputer systems may be used with or perform operations in accordancewith the teachings described herein.

In view of the wide variety of embodiments to which the principles ofthe present invention can be applied, it should be understood that theillustrated embodiments are exemplary only, and should not be taken aslimiting the scope of the present invention. For example, the steps ofthe flow diagrams may be taken in sequences other than those described,and more or fewer elements may be used in the block diagrams. Whilevarious elements of the preferred embodiments have been described asbeing implemented in software, in other embodiments in hardware orfirmware implementations may alternatively be used, and vice-versa.

Additionally, the system architecture depicted and described withrespect to FIGS. 1, 2 a and 2 b has been chosen to best illustrate theoverall functionality of the claimed invention. Splitting thefunctionality into a configuring subsystem, a business subsystem, aprocessing subsystem and a drawing subsystem was done for ease ofdiscussion. Physically, these subsystems do not have to be separate anddistinct subsystems with the functionalities assigned to each asdescribed herein. It will be apparent to a person of ordinary skill inthe relevant art how to implement alternative physical architecturescomprising fewer or more subsystems which together perform thefunctionality described herein.

It will be apparent to those of ordinary skill in the art that methodsinvolved in the automated injection molding configuring andmanufacturing systems may be embodied in a computer program product thatincludes a computer usable medium. For example, such a computer usablemedium can include a readable memory device, such as, a hard drivedevice, a CD-ROM, a DVD-ROM, or a computer diskette, having computerreadable program code segments stored thereon. The computer readablemedium can also include a communications or transmission medium, suchas, a bus or a communications link, either optical, wired, or wirelesshaving program code segments carried thereon as digital or analog datasignals.

FIG. 36 illustrates a block diagram for a preferred method 1000 of thepresent invention for high-speed assembling and manufacturing ofcustomized hot runner systems. As shown in FIG. 36, the method 1000preferably starts out with approximately 80% of the manufacturing andassembling of the hot runner systems and the standard manifolds A, B, Cbeing completed in a first phase, referred to herein as Phase 1 (seebelow). A customer may then place an order for the stocked, 80% completehot runner systems and choose between manifold A, B, and/or C. After anorder has been taken, the necessary manifold(s) and components areremoved from stock, and 100% of the manufacturing and assembling of thehot runner systems is completed in a second phase, referred to herein asPhase 2 (see below). The hot runner systems are completed based on thefactors specified in the customer's order, such as the nozzle pitches,X.

FIG. 37 shows a flow diagram illustrating the preferred method 1000 ofthe present invention in more detail. As shown in FIG. 37, the method1000 begins with Step 1012 wherein raw material is selected for aplurality of different manifold plates. In Step 1014, a variety ofdifferent standard manifold plates are manufactured by cutting andgrinding the selected raw material into various standard manifold plateshapes, configurations, and dimensions. In one exemplary embodiment ofthe method of the present invention, the selected raw material is steelthat is manufactured into one of a straight bar shape, X-shape, H-shape,Y-shape, Y-plate shape, or H-plate shape. In this exemplary method, eachmanifold plate may also be configured with a wide range of thickness,preferably from about 30 millimeters to about 37 millimeters, and theflow channels of the manifold plates may be configured with a wide rangeof diameters, preferably from about 3 millimeters to about 12millimeters. For more information on the various shapes, configurations,sizes, and styles of the manifold plates suitable for use with thepresent invention, see U.S. Pat. Nos. 4,761,343, 5,007,821, 5,030,084,5,441,197, 5,705,202, and 5,792,493, all of which are specificallyincorporated in their entirety herein by reference.

As shown in FIG. 37, the next Step in the method 1000 of the presentinvention is Step 1016, wherein heating element grooves are milled intothe manifold plates. In Step 1018, holes for any manifold attachments,such as melt inlet couplings, heating components, and/or manifoldlocators, connectors, and alignment pins, are then machined into themanifold plates. Next, the main flow channels are drilled (e.g., gundrilled) in the manifold plates in Step 1020. As previously mentioned,the diameters of the main flow channels are preferably in the range from3 millimeters to 12 millimeters.

In Step 1022, heating elements are inserted and installed into theheating element grooves that were previously milled into the manifoldplates. Any number of known methods may be used to manufacture andinstall such heating elements, including, but not limited to, brazing,press-in, plasma spray, and the like. For more information on suitablemethods for manufacturing and installing the heating elements for thepresent invention, see U.S. Pat. Nos. 3,095,604, 4,381,685, 5,496,168,4,439,915, 4,638,546, 4,688,622, WIPO Publication No. 99/20451, EuropeanPatent No. 425,981, and European Patent No. 262,490, all of which arespecifically incorporated in their entirety herein by reference.

The injection nozzles and plugs to be used with the manifold plates aremanufactured in Step 1024. Any of the injection nozzles disclosed anddescribed in the above incorporated patents may also be used with themethod of the present invention. Preferably, the injection nozzles mayhave a standard length from 36 millimeters to 380 millimeters, a flowchannel diameter from 3 millimeters to 12 millimeters, a shot weightrange from 0.1 grams to 1500 grams, a variety of different nozzle tipstyles, and may also be either thermal-gated or valve-gated. In oneexemplary embodiment of the method of the present invention, eachinjection nozzle may also manufactured to be adaptive for severaldifferent gate sizes in accordance with U.S. Pat. No. 4,579,520, whichis specifically incorporated in its entirety herein by reference. Usingan adaptive injection nozzle with the method of the present inventionfurther standardizes the injection nozzles, and reduces manufacturingand inventory costs, since fewer nozzles can cover more sizes.

An array of different plugs, with varying diameters and lengths, may beused in the method of the present invention. For instance, the plugs maybe designed to be inserted into, and oriented within, the bored holes ofthe manifold plates perpendicular and/or parallel to the main flowchannels in the manifold plates. For more information on plugs suitablefor use with the present invention, see U.S. Pat. Nos. 5,762,976,6,007,108, 5,441,197, 5,366,369, and European Patent No. 875,355, all ofwhich are incorporated in their entirety herein by reference. Inaddition to plugs, it should be understood that connector bushings mayalso be used with the method of the present invention. If connectorbushings are manufactured and used with the present invention, however,then preferably nozzle manifolds are also manufactured and used togetherwith the connector bushings for the method of the present invention. Formore information on connector bushings and manifold nozzles, see U.S.Pat. No. 5,792,493, which is specifically incorporated in its entiretyherein by reference.

As shown in FIG. 37, the method 1000 of the present invention continueswith Step 1026, wherein the manufactured manifold plates, nozzles,plugs, and other hot runner components (e.g., connector bushings andnozzle manifolds) are stored and placed in stock. Preferably, aselection of different manifold plates, nozzles, plugs, and other hotrunner components are manufactured and stocked in order to give acustomer a variety of options for manifold shapes, lengths, andthickness, nozzle types, sizes, and gate configurations, plug diametersand lengths, and combinations thereof. For purposes of the presentapplication, Steps 1012 through 1026 of the method 1000 will becollectively referred to herein as Phase 1. It should be understood,however, that more or fewer Steps may be included in Phase 1, and themethod 1000 of the present invention should not be limited to only theSteps of Phase 1 shown in FIG. 37 and described herein. In addition, itshould also be understood that the particular order of the Steps inPhase 1 is not necessarily critical, and may be rearranged, depending onmanufacturing preferences. Furthermore, it should be understood thatPhase 1 may be performed in a continuous loop nature to keep the stockedinventory at a full level.

The method 10 of the present invention continues with Step 1028, asshown in FIG. 37. In Step 1028, the hot runner maker takes a customerorder for a hot runner system, including the hot runner system'sspecifications selected from the provided ranges and optionscorresponding to the manifold plates, nozzles, plugs, and other hotrunner components in stock. For example, a customer may specify amanifold plate with any standard length between 150 millimeters and 600millimeters, any standard thickness from 25 millimeters to 40millimeters, and any standard flow channel diameters from 3 millimetersto 12 millimeters. The customer may also specify a straight bar shape,X-shape, H-shape, Y-shape, Y-plate shape, or H-plate shape manifoldplate, as well as the number of nozzles (e.g., 2 to 8) and the nozzlepitch (e.g., 30 millimeters to 250 millimeters). Finally, the customermay also specify the shapes, sizes, tip styles, gate configurations andshot weight ranges of the injection nozzles, depending on what nozzleshave been manufactured and placed in stock.

In Step 1030, the manifold plate, nozzles, and plugs corresponding tothe customer's order and specifications are removed from stock. Themethod 1000 proceeds with Step 1032, wherein the necessary holes andslots for the plugs are bored out in the manifold plate at the locationsset by the customer's order and hot runner system specifications. Forexample, if a customer specified a nozzle pitch range of 100millimeters, the holes and slots for the plugs would be bored out 100millimeters laterally from the melt inlet. As shown in FIG. 37, theholes for attaching the selected nozzles are then drilled in themanifold plate around the bored out holes and slots for the plugs inStep 1034.

Next, in Step 1036, the selected plugs are inserted and shrunk-fit intothe bored out holes of the manifold plate, with the alignment pins ofthe plugs being positioned in the alignment slots. To the extentnecessary, the manifold plate is then ground to its desired thickness inStep 1038. For instance, if a customer specified a 30 millimeter thickmanifold plate, and a 35 millimeter thick manifold plate was removedfrom stock in connection with the customer's order, the 35 millimeterthick stocked manifold plate would be ground to the desired 30millimeter thick manifold plate.

The method 1000 continues with Step 1040, wherein the selected injectionnozzles are attached to the drilled out holes in the manifold platesurrounding the plugs. The injection nozzles are attached to themanifold plate in a manner such that the melt channel of the nozzles isaligned and in communication with the melt passage of the plugs, whichin turn is aligned and in communication with the main flow channel. Anyother desired finishing to complete the hot runner system is done inStep 1042, and the customized hot runner system is then ready fordelivery to the customer.

For purposes of the present application, Steps 1028 through 1040 of themethod 1000 will be collectively referred to herein as Phase 2. Itshould be understood, however, that more or fewer steps may be includedin Phase 2, and the method 1000 of the present invention should not belimited to only the steps of Phase 2 shown in FIG. 37 and describedherein. In addition, it should also be understood that the particularorder of the steps in Phase 2 is not necessarily critical, and may berearranged, depending on manufacturing preferences.

FIGS. 38A-38J illustrate an exemplary embodiment of the method 1000 ofthe present invention, using a straight bar shape, two nozzle hot runnersystem. It should be understood that hot runner systems with othershapes, configurations, and styles may be used with the method of thepresent invention, and the straight bar shape, two nozzle hot runnersystem described herein and shown in FIGS. 38A-38J was chosen forillustrative purposes only. Moreover, the sizes and dimensions set forthin detail below may be different for other hot runner systems, anddifferent dimensions and sizes are contemplated for such other hotrunner systems.

As shown in FIG. 38A, a straight bar shaped manifold plate 1100 has afirst side 1102, a second side 1104 opposite the first side 1102, afirst end 1106, and a second end 1108 spaced from the first end 1106.The manifold plate 1100 is preferably selected from a steel material(Step 1012), and is manufactured with a standard length, L, and astandard thickness, T (Step 1014). Preferably, the length, L, is in therange from 300 millimeters to 600 millimeters, more preferably, in therange from 322 millimeters to 572.5 millimeters, and most preferably,either 322 millimeters, 372 millimeters, 422 millimeters, 472.5millimeters, 522.5 millimeters, or 572.5 millimeters. Similarly, thethickness, T, is preferably in the range from 25 millimeters to 40millimeters, more preferably in the range from 30 millimeters to 37millimeters, and most preferably 30 millimeters.

As shown in FIG. 38B, a heating element groove 1110 is milled into thefirst side 1102 of the manifold plate 1100 (Step 1016). A melt inlet1112, as well as holes 1114 for receiving a melt inlet coupling (notshown) are drilled into the second side 1104 of the manifold plate 1100(Step 1018), as shown in FIG. 38C. In addition, a main flow channel 1120is drilled in the manifold plate 1100 (Step 1020). The main flow channel1120 preferably has a lateral portion 1122 extending from the first end1106 to the second end 1108 of the manifold plate 1100. The main flowchannel 1120 preferably also has an inlet portion 1124 extendingbetween, and in communication with, the melt inlet 1112 and the lateralportion 1122 of the main flow channel 1120. The diameter of the mainflow channel is preferably in the range from 3 millimeters to 12millimeters, and depends on the size of the manifold plate 1100 and thetype of material being used with the hot runner system.

As shown in FIGS. 38D-38F, a heating element 1130 is inserted andinstalled into the heating element groove 1110 in the first side 1102 ofthe manifold plate 1100 (Step 1022). As discussed above, the heatingelement 1130 may be fixed within the heating groove 1110 via a brazing,press-fit, plasma spray, or other like method readily known in the art.The power of the heating element 1130 at 220 volts is preferably in therange from 1650 watts to 2800 watts, depending on the size of themanifold and the type of material being used with the hot runner system.

The manifold plate 1100 is now ready to be stocked. Although not shown,it should be understood that a number of standard nozzles and plugs havealready been manufactured (Step 1024) and placed in stock together withthe manifold plate (Step 1026). Accordingly, Phase 1 has been completedas of FIG. 38F.

Phase 2 then begins with a customer placing an order for a straight barshaped, two nozzle hot runner system (Step 1028), and the correspondingcomponents being removed from stock (Step 1030). As shown in FIGS.38G-38H, a first bore 1140 and a first alignment slot 1142, as well as asecond bore 1144 and a second alignment slot 1146, are then bored out ofthe manifold plate 1100 (Step 1032). The locations of the bores 1140,1144 and the corresponding alignment slots 1142, 1146 depend on thenozzle pitch, X, specified by the customer's order (see Step 1028). Asknown in the art, the nozzle pitch, X, is generally defined as thelateral distance between the center of the melt inlet and the center ofa nozzle, which is typically also the center of a plug and itscorresponding bore. The below Table 1 includes preferable nozzle pitch,X, ranges for several different manifold plate lengths, L,:

TABLE 1 X L 100.00-125.00 322.0 125.01-150.00 372.0 150.01-175.00 422.0175.01-200.00 472.5 200.01-225.00 522.5 225.01-250.00 572.5

In addition to the first and second bores 1140, 1144 and the first andsecond alignment slots 1142, 1146, a plurality of nozzle holes 1148 arealso drilled in the manifold plate 1100 around the first and secondbores 1140, 1144 (Step 1034). As shown in FIGS. 38I-38J, a first plug1150 having a first alignment pin 1151 and a first plug channel 1152 isinserted and press fit into the first bore 1140 (Step 1036). Likewise, asecond plug 1154 having a second alignment pin 1155 and a second plugchannel 1156 is inserted and shrunk fit into the second bore 1144 (Step1036). Preferably, the first and second alignment pins 1151, 1155 arepositioned within the first and second alignment slots 1142, 1146,respectively. In addition, the first and second plug channels 1152, 1156are aligned and in communication with the lateral portion 1122 of themain flow channel 1120.

Although not shown, the manifold plate may be ground to its desiredthickness (Step 1038), if necessary, and the nozzles may be attachedwith fasteners (not shown) to the manifold plate 1100 via the nozzleholes 1148 (Step 1040). Any other finishing steps may then be performedon the customized hot runner system before it is eventually delivered toits customer (Step 1042).

As previously mentioned, it should be understood that manifold platesother than the straight bar shaped, two nozzle type shown in FIG. 38Jmay be used with the method of the present invention. For instance, anX-shaped, four nozzle manifold plate or an H-shaped, four nozzlemanifold plate may be used with the method of the present invention.Accordingly, a detailed example of the straight bar shaped, two nozzlemanifold plate is not only shown in FIG. 38K, but detailed examples ofX-shaped and H-shaped, four nozzle manifold plates are shown in FIGS.38L-38M, respectively. Tables identifying preferred nozzle pitches andmanifold dimensions (e.g., manifold length, L,) for each of thesemanifold plate types are also included in FIGS. 38K-38M.

FIG. 39 shows the proper positioning and alignment for the first plug1150 within the first bore 1140 of the manifold plate 1100. To avoidredundancy and unnecessary repetition, only the first plug 1150 is shownin FIG. 39, since the second plug 1154 is similarly situated andinstalled. As shown in FIG. 39, the first plug 1150 is preferablypositioned within the first bore 1140 such that the first plug 1150 isflush and even with the manifold plate 1100, and the first plug channel1152 is aligned and in communication with the lateral portion 1122 ofthe main flow channel 1120. The first plug 1150 is also positionedwithin the first bore 1140 of the manifold 1100 such that the first plugchannel 1152 is aligned and in communication with a central melt passage1165 of a nozzle 1160, as shown in FIG. 39.

As shown in FIG. 40, the first plug 1150 may alternatively be rotated90° and positioned parallel to the lateral portion 1122 of the main flowchannel 1120, rather than perpendicularly, as shown in FIG. 39. For easeof reference, this rotated first plug will be referred to herein by thereference numeral 1150′. FIG. 41 illustrates the proper positioning ofthe first plug 1150′ within the manifold plate 1100. In thisarrangement, the first bore 1140 and the first alignment slot 1142 arerotated 90° to a modified first bore 1140′ and a first alignment slot1142′. As shown in FIG. 41, the first plug 1150′ is inserted into themanifold plate 1100 parallel with the lateral portion 1122 of the mainflow channel 1120 such that the first plug channel 1152 is aligned inthe communication with the lateral portion 1122 of the main flow channel1120, as well as an auxiliary flow channel 1170 that is aligned and incommunication with a central melt channel 1165 of a nozzle 1160. Anyauxiliary flow channel 1170 is preferably drilled at the same time thatthe modified first bore 1140′ and the first alignment slot 1142′ arebored out of the manifold plate 1100.

The method of the present invention may be applied with particularadvantage to situations where a customized hot runner system needs to bequickly manufactured and assembled for a customer. By conducting most ofthe manufacturing and assembling for the hot runner system prior to acustomer placing an order, the amount of manufacturing and assemblingthat needs to be done after a customer places an order for a hot runnersystem is minimized, thereby dramatically decreasing the amount of timerequired to fulfill a customer's order for a hot runner system.Moreover, by manufacturing, assembling, and stocking only standardmanifold plates, injection nozzles, and plugs that can readily becustomized to fit a customer's order, inventory costs can also beminimized.

It should also be readily apparent from the forgoing description andaccompanying drawings that method of the present invention is animprovement over the prior art methods for manufacturing and assemblinghot runner systems. For instance, the method of the present inventionuses a variety of standard stock manifold plates, nozzles, and plugs forhigh-speed manufacturing and assembling of hot runner systems, whilestill providing customers with numerous options and tremendousflexibility for ordering and customizing their hot runner systems. Inaddition, unlike prior art methods, a multitude of customers cansimultaneously receive fast manufacturing and assembling of theircustomized hot runner systems with the method of the present invention.In other words, with the method of the present invention, customerorders do not have to be put on hold or delayed to accommodate morepressing rush orders.

The method of the present invention is well suited for use with anonline ordering system, such as an Internet-based hot runnerconfiguration system. The assignee of the present invention operatessuch a system, named Merlin™, which is suitable for use with the methodof the present invention. For more information on Merlin™, see the URL“www.moldmasters.com” and the commonly assigned U.S. patent applicationSer. No. 09/595,154, filed Jun. 16, 2000, entitled “Method and Apparatusfor an Automated Injection Molding Configuring and ManufacturingSystem,” and specifically incorporated by reference herein in itsentirety.

Those skilled in the art to which the invention pertains may makemodifications and other embodiments employing the principles of thisinvention without departing from its spirit or essentialcharacteristics, particularly upon considering the foregoing teachings.Accordingly, the described embodiments are to be considered in allrespects only as illustrative and not restrictive and the scope of theinvention is, therefore, indicated by the appended claims rather than bythe foregoing description. Consequently, while the invention has beendescribed with reference to particular embodiments, modifications ofstructure, sequence, materials and the like would be apparent to thoseskilled in the art, yet still fall within the scope of the invention.

1. A method for use in designing a customized hot-runner system using anonline computer system connected to a computer network, the methodcomprising: establishing hot-runner component options to be selected bya user, the hot-runner component options including manifold types,nozzle types, and nozzle pitches; providing a user input screen on whichthe hot-runner component options to be selected by a user are displayed;electronically receiving selected hot-runner component options from theuser input screen, the selected hot-runner component options including aselected manifold type, a selected nozzle pitch, and a selected nozzletype; processing the selected hot-runner component options to create acustomized hot-runner system configuration based on the selectedhot-runner component options; and generating a drawing of the customizedhot-runner system automatically from the customized hot runner systemconfiguration.
 2. The method of claim 1, wherein the user input screencomprises an Internet Web page or an Intranet Web page.
 3. The method ofclaim 1, wherein the user input screen includes a form into whichinformation is inputted.
 4. The method of claim 1, wherein thehot-runner component options are at least partially selected by acustomer.
 5. The method of claim 1 further comprising indicating arecommended hot-runner component option based on a hot-runner componentoption that was previously selected.
 6. The method of claim 1 furthercomprising notifying a verifying person to review the selectedhot-runner system configuration.
 7. The method of claim 6, whereinnotifying the verifying person comprises sending an electronic mail tothe verifying person.
 8. The method of claim 7 further comprisingsending an electronic mail confirmation to a user who selected thehot-runner system configuration regarding the review.
 9. The method ofclaim 1 further comprising saving the selected hot-runner systemconfiguration on a computer.
 10. The method of claim 1 furthercomprising loading a previously saved hot-runner system configurationfrom a computer.
 11. The method of claim 1 further comprising providingthe drawing to a customer.
 12. The method of claim 1 further comprisingsending an electronic mail to a customer, the electronic mail includinga hyperlink to access the drawing.
 13. The method of claim 1, whereingenerating the drawing automatically comprises generating athree-dimensional model of the selected hot-runner system automatically.14. The method of claim 1 further comprising calculating a cost of thehot-runner system based on the selected hot-runner system configurationand displaying a quote for the hot-runner system based on the selectedhot-runner system configuration.
 15. The method of claim 1 furthercomprising determining a schedule for completing the hot-runner systembased on the selected hot-runner system configuration.
 16. The method ofclaim 1 further comprising receiving an order for the hot-runner systembased on the selected hot-runner system configuration.
 17. The method ofclaim 16 further comprising displaying a status of the orderedhot-runner system.
 18. The method of claim 1 further comprisingmanufacturing the hot-runner system according to the selected hot-runnersystem configuration.
 19. The method of claim 18, wherein manufacturingthe hot-runner system comprises: before receiving the selectedhot-runner component options, partially manufacturing manifolds of themanifold types; and after receiving the selected hot-runner componentoptions and processing the selected hot-runner system configuration,continuing manufacture of a manifold of the selected manifold type andassembling the manifold and a nozzle of the selected nozzle type,according to the selected hot-runner system configuration, to form thehot-runner system.
 20. The method of claim 19, wherein partiallymanufacturing the manifold comprises making a main flow channel in themanifold.
 21. The method of claim 20, wherein the diameter of the mainflow channel depends on a molding material specified by a customer. 22.The method of claim 19, wherein continuing manufacture of the manifoldcomprises making an auxiliary flow channel in the manifold, theauxiliary flow channel to be in communication with a central meltchannel of the nozzle.
 23. The method of claim 1 further comprisingreceiving at least one of a selected molding material and a selectedshot weight.
 24. The method of claim 1 further comprising establishingadditional hot-runner component options to be selected by a userincluding at least one of gate types, a gate seal, a gate insert, avalve actuator, an inlet component, an inlet component manifold centerheater, a location ring, and a molding elevation, and wherein theselected hot-runner system configuration additionally includes at leastone of a selected gate type, a selected gate seal, a selected gateinsert, a selected valve actuator, a selected inlet component, aselected inlet component manifold center heater, a selected locationring, and a selected molding elevation.
 25. The method of claim 1further comprising receiving at least one of a selected manifolddimension and a selected nozzle placement.
 26. The method of claim 1,wherein manifold types comprise at least one of a straight bar shape, anX-shape, an H-shape, a Y-shape, a Y-plate shape, or an H-plate shape.27. The method of claim 1, wherein establishing the option of nozzlepitches comprises establishing a range of nozzle pitches correlating toan option of manifold type or manifold size.
 28. The method of claim 1,wherein the selected hot-runner system configuration is electronicallyreceived at a local computer or a local server from a remote computer.29. A method for use in designing a customized hot-runner system usingan online computer system connected to a computer network, the methodcomprising: establishing hot-runner component options to be selected bya user, the hot-runner component options including manifold types,nozzle types, and nozzle pitches; providing a user input screen on whichthe hot-runner component options to be selected by a user are displayed;electronically receiving selected hot-runner component options from theuser input screen, the selected hot-runner component options including aselected manifold type, a selected nozzle pitch, and a selected nozzletype; processing the selected hot-runner component options to create acustomized hot-runner system configuration based on the selectedhot-runner component options; and calculating a cost of the customizedhot-runner system automatically based on the selected hot-runner systemconfiguration and displaying a quote for the customized hot-runnersystem based on the selected hot-runner system configuration.
 30. Themethod of claim 29, wherein the user input screen comprises an InternetWeb page or an Intranet Web page.
 31. The method of claim 29, whereinthe user input screen includes a form into which information isinputted.
 32. The method of claim 29 further comprising indicating arecommended hot-runner component option based on a hot-runner componentoption that was previously selected.
 33. The method of claim 29 furthercomprising generating a drawing of the hot-runner system automaticallyfrom the hot runner system configuration.
 34. The method of claim 29further comprising notifying a verifying person to review the selectedhot-runner system configuration.
 35. The method of claim 34, whereinnotifying the verifying person comprises sending an electronic mail tothe verifying person.
 36. The method of claim 29 further comprisingdetermining a schedule for completing the hot-runner system based on theselected hot-runner system configuration.
 37. The method of claim 29further comprising receiving an order for the hot-runner system based onthe selected hot-runner system configuration.
 38. The method of claim 37further comprising displaying a status of the ordered hot-runner system.39. The method of claim 29 further comprising manufacturing thehot-runner system according to the selected hot-runner systemconfiguration.
 40. The method of claim 39, wherein manufacturing thehot-runner system comprises: before receiving the selected hot-runnercomponent options, partially manufacturing manifolds of the manifoldtypes; and after receiving the selected hot-runner component options andprocessing the selected hot-runner system configuration, continuingmanufacture of a manifold of the selected manifold type and assemblingthe manifold and a nozzle of the selected nozzle type, according to theselected hot-runner system configuration, to form the hot-runner system.41. The method of claim 40, wherein partially manufacturing the manifoldcomprises making a main flow channel in the manifold.
 42. The method ofclaim 40, wherein continuing manufacture of the manifold comprisesmaking an auxiliary flow channel in the manifold, the auxiliary flowchannel to be in communication with a central melt channel of thenozzle.
 43. The method of claim 29, wherein the selected hot-runnersystem configuration is electronically received at a local computer or alocal server from a remote computer.